Two unit dry stack masonry wall system

ABSTRACT

A mason wall cementitious building block system comprising two lightweight dry-stackable block units and methods of using such units, including a wall unit and a corner/end unit, connected one to another in an interlocking fashion by means of male posts and female sockets, and variants on each of said units for capping the uppermost course of an assembled wall. The male posts angle rearwardly to define partial apertures, such that adjoining blocks define an aperture which extends vertically between the adjoined blocks for placement of vertical reinforcement, electrical and plumbing chase, and for the introduction of mortar or cement. The top surface defines a recessed cavity for placement of rebar when stacked. The corner/end unit of the present invention interconnects with wall units also by means of posts and sockets and may function as either an end or a corner, requiring only the removal of a small portion of the block at prescored cut lines to alter functions. 
     The wall cap and corner and end caps interconnect with staggered end headers and include partial adjoining apertures to continue vertical apertures formed by lower courses. Methods of assembling walls from the blocks are disclosed.

This application claims benefit of Provisional application Ser. No.60/084,557, filed May 6, 1998.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to unit-shaped masonry blocks, and morespecifically to dry-stackable masonry unit configurations and methods oferecting dry-stackable masonry unit structures.

2. Description of the Prior Art

Masonry construction blocks and methods for constructing various kindsof brick or block walls are well known in the art. Because of thedifficulty and high cost of constructing walls of quarried stone orblock, cast cementitious blocks long ago replaced quarried stone as apreferred material in many applications.

Cast blocks typically have a uniform size and shape, include at leastone cavity, and frequently permit physical interlocking, eithervertically or horizontally, with integrally formed or independentconnection means. Such interlocking designs facilitate rapid assemblyand proper alignment during fabrication. They also permit assemblywithout mortar, so that some designs of cast blocks may be employed fortemporary walls that can be easily disassembled.

Walls constructed of cast blocks may rely exclusively on the mass of theblocks to maintain alignment and stability. However, mortarlesscementitious cast block walls intended for permanent use usually requireadditional stability. Accordingly, many designs permit mortar orreinforced concrete to be poured or injected into and to fill gaps andaligned vertical and horizontal openings in the blocks.

However, along with their advantages, the known cast blocks also havemany disadvantages, including: difficulty in converting the wall unitsinto end or corner units; lateral instability; vulnerability of exposedmortar to chemical or environmental degradation; expansion andcontraction of mortar, causing cracking and separation of blocks;difficulty in constructing curved configurations; and vulnerability ofbroad flat surfaces to defacement and graffiti.

SUMMARY OF THE INVENTION

The present invention is a mason wall cementitious building block systemcomprising two lightweight dry-stackable block units and methods ofusing such units. The blocks include a wall unit and a corner/end unit,and corresponding variations on each to function as cap units. Adjoiningwall units and corner/end units connected one to another in aninterlocking fashion. Caps for each of these units interconnect withadjoining caps via ends of staggered lengths. The unit shapes, themethods of assembling walls of such units, and the walls constructed ofsuch units, overcome the limitations of the prior art.

The wall unit of the present invention comprises a front face, a rearface, an upper face, a lower face, two sides, two male posts projectingfrom said sides, and two female sockets integrally formed in said sides.In a preferred embodiment, two holes extend vertically through the blockfor engagement with raised stops on blocks of inverted position stackedeither below or above. The male posts angle back from the front facetowards the rear face and terminate in a rounded enlarged head forinterconnection with the female socket of an adjoining block. Eachrearwardly angled male post defines a partial aperture at the side ofthe block, such that interconnected adjoining blocks in an assembledwall define an aperture which extends vertically between the adjoinedblocks for placement of vertical reinforcement rebar, the introductionof mortar or cement, and plumbing and electrical chase, as needed. Thetop face defines a shallow recess located in approximately the middle ofthe block and running the length of the block essentially parallel tothe front and rear faces.

The corner/end unit of the present invention comprises an end face, onemale post, one defined female socket, and a potential female socketdefined by an interior cylindrical aperture extending vertically throughthe block. This unit may function as either an end or a corner,requiring only the removal of a small portion of the block at prescoredcut lines for use as a corner.

The wall cap unit comprises outer faces, two sides with a shortprojection extending from and a short recess extending into oppositesides of partial arcuate apertures at each side, a bottom surface, and arecess extending into the top bed face and running along its entirelength generally parallel to the outer faces. The upper portion of theouter face is decoratively beveled. Corner caps have the same structureas wall caps, but with a right angle introduced at the longitudinalmidpoint. The end cap unit is essentially a truncated wall cap unit witha single partial aperture, an end face, and a recess extending into thetop bed face that terminates short of the interior border of the endface.

A method of erecting structures comprised of the above-described unitscomprising the steps of:

1. Forming a poured-in-place concrete footing with embedded verticalreinforcement;

2. Stacking a plurality of courses of block as described above inrunning bond, stepped, or stacked bond layouts with the male posts ofblocks interconnected with the female sockets of adjoining blocks toalign and fix the blocks in position and to define a vertical aperturebetween adjoining blocks for placement of the vertical reinforcement andselected electrical and plumbing chase;

4. Laying horizontal rebar in the aperture defined by one courseoverlying another;

5. Placing a post tension clamp over the vertical rebar until it nestson horizontal rebar and tightening the clamp to cut into verticalrebars;

6. In the case of permanent walls, pouring mortar or concrete into atleast some of the vertical apertures to flow through said apertures andinto horizontal apertures to form a continuous joint between adjoiningblocks, leaving the front and rear faces exposed.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top view of a first embodiment of a dry-stackable cast blockwall unit according to the present invention.

FIG. 2 is a top view of an alternative embodiment of a dry-stackablecast block wall unit, illustrating a fluted, split face design.

FIG. 3 is a top view of a dry stackable cast block corner/end unitaccording to the present invention.

FIG. 4 is a top view of yet another alternative embodiment of adry-stackable cast block wall unit, illustrating a fluted split facedesign especially well-suited for sound walls in a stacked bond layoutwith half height alternating starter course interlocks course to course.

FIG. 5 is a plan view of a single level of a running bond course of thepresent invention utilizing the wall unit embodiment of FIG. I and thecorner/end of FIG. 3, and further illustrating horizontal rebar layout.

FIG. 6 is a side view of a cross-section stacked bond layout, notshowing rebar layout.

FIG. 7 is an end view of a running bond course, not showing rebarlayout.

FIG. 8 is a plan view of a stacked bond alternating half-height starterlayout using fluted/split face design blocks as illustrated in FIG. 2,and showing rebar layout.

FIG. 9 is an end view of the layout of FIG. 8.

FIG. 10 is a plan view of a stepped layout, showing rebar layout.

FIG. 11 is an end view of the layout of FIG. 10.

FIG. 12 is a top view of a dry-stackable cast block wall cap unit of thepresent invention.

FIG. 13 is a side view of the wall cap unit of the present invention.

FIG. 14 an end view of the wall cap unit.

FIG. 15 is a top view of the end cap unit of the present invention.

FIG. 16 is a side view of the end cap unit.

FIG. 17 is an end view of the end cap unit.

FIG. 18 is a plan view of a wall cap and end cap layout, showing rebarlayout and tension-compression clamp placement.

FIG. 19 is an end view of a running bond layout showing rebarreinforcement and tension-compression clamp placement in the superiorcavity of a wall cap as shown in FIG. 14.

FIG. 20 is an enlarged view of a tension-compression clamp of the kindthat may be used to secure the superior end of vertical rebarreinforcement in a wall assembly of the present invention.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT

The present invention comprises two primary cast block units forconstructing a dry-stackable masonry wall, and variants on said unitsfor capping the uppermost course of an assembled wall. The primary unitsinclude a wall block unit and a corner/end block unit, and the cappingunits include a wall cap, corner cap, and an end cap. For simplicity thesame numerals shall be used herein to refer to functionally identicalelements in each of the various units.

The drawings show six embodiments of the masonry units of the presentinvention. FIGS. 1, 2 and 4 illustrate embodiments of the wall unit ofthe invention. FIG. 3 illustrates the corner/end unit of the presentinvention. FIGS. 12-18 illustrate the wall cap, corner cap, and end capof the present invention. FIGS. 5-11 and 18-20 show various layouts forconstructing dry-stackable masonry walls of the invention.

The masonry units of the present invention may be composed of any numberof suitable materials, including various polymers, although thepreferred materials are cementitious.

1. Wall Unit

FIG. 1 is a top view of a first embodiment of the dry-stackable castmasonry wall unit according to the present invention, and is generallyillustrated by reference 10. The wall unit according to this firstpreferred embodiment comprises a front face 12, a rear face 14, an upperface 16, two male posts 20, and two female sockets 24. A lower face 18(not shown in FIG. 1), is shown in FIGS. 6 and 7 in two end views ofstacked wall units. In the first embodiment, two small diameter holes 28extend vertically through the block for engagement with raised stops 30on blocks of reversed position stacked either below or above, and thusfunction to facilitate mating of stacked blocks and to secure the blocksin place when positioned.

The male posts 20 angle back from the front face 12 towards the rearface 14 at an approximately 133 degree angle and terminate in a enlargedcylindrical head 22 for interconnection with the female socket 24 of anadjoining block, in the fashion of an anatomical ball and socket joint.This interconnection assists in the stacked alignment of the block andprovides increased lateral stability and resistance to shear forces. Therearwardly angled male posts 20 define partial apertures 26, such thatwhen adjoining blocks are interconnected a complete aperture 46 isdefined which extends vertically between the adjoined blocks forelectrical and plumbing chase, and for placement of verticalreinforcement rebar and the introduction of mortar or cement, as isshown in FIG. 5. Additionally, the male posts and female sockets areadapted to be rotated slightly with respect to one another so as toallow construction of curved walls.

The top surface defines a shallow recess 32 located in approximately themiddle of the block and running the length of the block at its middleportion essentially parallel to the front and rear faces. When mortar ispoured into apertures 46 as described above, it also flows horizontallyalong the rebar layout and into recesses 32 between the upper surface 16and the lower surface 18 of the block immediately above it.

FIG. 2 is a top view of an alternative embodiment of a dry-stackablecast block wall unit, illustrating a fluted, split face design with aroughly finished surface and semicircular concavities 36 in the frontand rear faces. Any number of forms may be incorporated into the frontand rear faces to give them an ornamental or decorative appearance in anassembled structure. In this second preferred embodiment, a taperedaperture 34 extends vertically through the block to define a centerhole. This aperture may be expanded longitudinally according to the sizeof the block and serves a number of functions, including aiding inportability, weight reduction in molding, and a cavity for fill orreinforcement in certain applications.

FIG. 4 is a top view of a third preferred embodiment of a dry-stackablecast block wall unit, illustrating a fluted split face design especiallywell-suited for sound walls. The block is shown interconnected withadjoining blocks in a stacked bond layout with half height alternatingstarter course interlocks course to course. This figure also illustrateshow the tapered aperture may be expanded in larger variations of thewall unit.

2. Corner/End Unit

FIG. 3 is a top view of a dry stackable cast block corner/end unitaccording to the present invention. This unit has an end face 38, onemale post 20, one actually defined female socket 24, and a potentialfemale socket defined by an interior cylindrical aperture 44 extendingvertically through the block. When functioning as an end unit, the unitis left intact as depicted, and the open aperture female socket 24interconnects with the male post of an adjoining wall unit block. Whenfunctioning as a corner unit, a portion of the block is removed bycutting along the cut lines 42 through the female socket 24 and the cutline channel 40 to the interiorly defined cylindrical aperture 44. Whencut in this fashion, the cylindrical hole 44 becomes an open aperture ofthe same shape and size as a female socket and thus interconnects withthe male post of an adjoining block positioned at a substantially rightangle to the corner unit.

3. Wall Cap, End Cap, and Corner Cap Units

FIGS. 12, 13, and 14, show top, side, and end views, respectively, of adry-stackable cast block wall cap unit of the present invention. Thisunit comprises two outer faces 52, two ends 54, a top bed face 56, twopartial adjoining apertures 58 at opposite ends of the length of theunit, a bottom surface 60, and a recess extending into the top bed faceand running along its entire length generally parallel to the outerfaces. The upper portion 68 of the outer face 52 is beveled. The endsare of staggered length as defined by a short projection extendinglongitudinally at the side of the partial aperture on its respective endand a correspondingly short recess extending longitudinally into theblock side at the opposite side of the partial aperture, so as tofacilitate alignment and mating with adjoining wall caps or end caps andto increase stability.

Corner caps, shown only in layout (see FIG. 18), have the same structureas wall caps, but with a right angle introduced at the longitudinalmidpoint.

FIGS. 15, 16, and 17, are top, side, and end views, respectively, of theend cap unit of the present invention. This unit is essentially atruncated wall cap with two outer faces 52, one side 54, a singlepartial aperture 58, an end face 64 with a beveled upper portion 68, anda recess extending into the top bed face 56 which terminates short ofthe interior border of the end face.

5. Method of Constructing Dry-Stackable Masonry Unit Wall

The blocks of the present invention may be used in a variety ofstructural configurations. Preferably the masonry system is constructedupon a standard poured-in-place concrete footing with embedded verticalreinforcement, preferably provided at approximately 8 inch to 10 inch oncenter. A level footing and proper placement of reinforcement isachieved by using a 2×4 or edge at footing height and securing #4 or #5rebars to each side of the 2×4. Rebar layout is simplified by beginningthe 8 or 10 inch layout 6 inches in from any end or corner. With thefooting finished level with the bottom edge of the 2×4, the footing willprovide the necessary straight and level surface to begin laying theunits. Curved walls may be laid using laminated 1×4's and the same rebarlayout. Alternatively, the first course may be laid without pouredfootings.

For the standard running bond installation, FIG. 7, the lower course islaid by placing blocks adjacent to each other, either end to end orcorner to corner. Each wall unit is laid with the upper surface 16 down,such that the upper surface recess 32 overlays the flat lower surface 18of the block. This requires that the raised stops 28 be chipped from thefirst course only; subsequent courses are alternated such that theraised stops 28 fit into the through holes 30 of the preceding course.

For a stacked bond installation, FIG. 6, the first course is laid withthe upper surface 16 down and the succeeding courses are alternatelyinverted.

In the standard running bond installation, alternating layout, FIGS. 5and 8, it can be seen that for a given course adjacent blocks interlockvia male posts 20 and female sockets 24, and thereby form a series offillable vertical apertures or cavities 46 and horizontal apertures orcavities 32 for the placement of horizontal rebar 48 and vertical rebar50 and the introduction of mortar or concrete. The same cavities andreinforcement schedules apply to a stacked bond layout with alternatinghalf-height starter, FIGS. 8-9, and stepped layouts, FIGS. 10-11. Therunning bond installation comprises alternating front and rear faces ona given course, thus creating alternating recesses located at each rearface 14. This produces an attractive wall finish which is anunattractive target for defacement by graffiti vandals.

FIG. 18 is a plan view of the wall cap, corner cap, and end cap layoutof the present invention, showing horizontal rebar layout 48, verticalrebar placement 50, and tension-compression clamp placement 70. FIG. 19is an end view of a running bond layout showing vertical rebarreinforcement 50 and tension-compression clamp placement 70 in thesuperior cavity 62 of a wall cap as shown in FIGS. 12-14. FIG. 20 is anenlarged view of a tension-compression clamp 70 of the kind that may beused to secure the superior end of vertical rebar reinforcement 50 in awall assembly of the present invention.

As can be seen, the cavities created by adjoining partial apertures 58complement and continue the same cavities 46 formed by adjoining unitslaid in lower courses. Horizontal rebar is laid over the superiorsurface of the top bed face to complete the last course, and atension-compression clamp 70 is placed over the superior ends ofvertical rebar 50 and secured at the conjunction with the horizontalrebar. See FIG. 19. Mortar or concrete may be poured into the cavitiesdefined by adjoining units to flow through the cavities and form acontinuous joint around the blocks while leaving the front and rearfaces exposed and virtually free of excess slurry.

Due to the post and socket fit, spacing between units is adjustablewithin limits. Thus, walls constructed of the blocks of the presentinvention are adaptable to the constraints of terrain. In high walls,areas with a hump in the footing may have units spaced as closelytogether as possible, while areas with dips may have units pulled apartas far as possible. This will allow the top of the wall to lengthen orshorten as necessary, to a maximum of one-half inch per unit.

Horizontal reinforcement 48 may be installed on any given course ofrunning bond. A ¾ inch dobbie is placed in the center of the wall unitat approximately 30 inch intervals and tied to the rebar. The correctfront-to-back placement will be automatically achieved by the posts ofthe units in the next course. Additionally, proper placement of thevertical rebar 50 is secured by the use of a rebar spacer tie which alsoprevents up lift while being vibrated with a mechanical vibrator. Whilea maximum lift of four feet is standard, a lift of two feet will notrequire mechanical vibration and can be consolidated by rodding with arebar dowel.

End units require no special attention. The post 20 and socket 24 ofthis unit are preferably slightly larger and smaller, respectively, thanthose of the wall unit to assist in proper alignment and to preventmovement during mechanical vibrating. Corner units require that one postbe cut or broken off from a wall unit and two cuts along prescored cutlines 42 of the end unit. The corner is then laid in the typicalalternating pattern for running bonds or stacked in one direction only.Horizontal reinforcement is carried through the corner on any givencourse.

The masonry system of the present invention is designed to meet thespecifications required for a coarse grout mix, which may be pumped inplace and mechanically vibrated or poured in place and rodded by handwith a rebar dowel. Clean up of excess slurry from between the unitswith a water hose, nozzle and small trowel should begin as soon asgrouting is completed.

While the post and socket design of the present invention allows forconsiderable flexibility in construction tolerances and techniques, theyare equalled by the variable possibilities for architectural design withonly a few finishes or colors. For example, quoins may be highlighted atcorners and ends by simply changing the colors. The apparent depth ofthe recess may be dramatized or negated with a similar change of color.

On large walls of any height or length, a half-height block unit may beemployed for more cost-effective construction and a more architecturallypleasing finish. For smaller scale projects a proportionately smallerversion may be desirable. While of the same design, it would have arebar layout of approximately 8 inch on center for added structuralintegrity, but would also have the appearance of delicately interwovenbrick work.

The masonry system of the present invention is inherently flexible andversatile with a minimum of bearing cross section. It may be employedfor either free standing or retaining walls. It may be either straightor curved vertical or stepped, and laid out in running or stacked bonds.Its unique design minimizes manufacturer materials, on-site labor, andskill requirements for construction. It is self-aligning, eliminatesvertical gaps, follows minor footing contours, provides bond beam on anycourse, improves sound attenuation, allows continuous reinforcement,improves design, and discourages graffiti.

While this invention has been described in connection with preferredembodiments thereof, it is obvious that modifications and changestherein may be made by those skilled in the art to which it pertainswithout departing from the spirit and scope of the invention.Accordingly, the scope of this invention is to be limited only by theappended claims.

What is claimed as invention is:
 1. A cast dry-stackable masonry blockfor constructing an interconnected wall of a plurality of said blocks,comprising: a front face; a rear face; a first side; a second side; afirst male post projecting outwardly and rearwardly from said firstside, said first male post terminating in a generally cylindricalenlargement and positioned so as to mate with an aperture of anadjacently positioned block; a second male post projecting outwardly andrearwardly from said second side, said second male post terminating in agenerally cylindrical enlargement and positioned so as to mate with anaperture of an adjacently positioned block; a first female socketintegrally formed as a radial aperture in said first side and positionedfor receivably mating with an adjacently positioned block, the apertureof said first female socket describing an arc of at least 180 degrees; asecond female socket integrally formed as a radial aperture in saidsecond side and positioned for receivably mating with an adjacentlypositioned block, the aperture of said second female socket describingan arc of at least 180 degrees; an upper face; and a lower face.
 2. Theblock of claim 1 wherein each of said first and second male posts andfirst and second female sockets have relative sizes adapted to permitrotation of the male posts and the female sockets within which it ismated such that a curved wall may be constructed from a plurality ofsuch blocks.
 3. The block of claim 1 wherein said upper face has atleast one small diameter circular hole extending vertically through theblock, and at least one small diameter cylindrical raised projection,such that when stacked with other of said blocks said hole will matewith the raised projection of a block in reversed position immediatelyabove and/or immediately below said block.
 4. The block of claim 1wherein said upper face defines a shallow recess located inapproximately the middle of the block and running the length of theblock at its middle portion essentially parallel to the front and rearfaces, such that said shallow recess is of sufficient depth toaccommodate #4 or #5 rebar laid horizontally across said recess.
 5. Theblock of claim 1 wherein said first and second male posts projectrearwardly from the front face towards the rear face at an approximately133 degree angle.
 6. The block of claim 1 wherein said front and rearfaces are smoothly finished concrete.
 7. The block of claim 1 whereinsaid front and rear faces are fluted, split faces with a rough concretefinish.
 8. The block of claim 7 wherein said block further includes atapered aperture extending vertically through the middle of said blockto define a center hole.